GKF 500 GKF 3000 The compact capsule filling machine for high performance 1
Flexibility and economy in operation for capsule filling Whichever products you would like to fill powders, pellets, tablets, liquids, micro-dosing or combinations, the GKF 500 offers a great solution in the high-speed production range. The design of this capsule filler allows for quick and complete cleaning, as well as efficient changeovers. The GKF 500 fulfills all modern cgmp requirements in the process, setting new standards in pharmaceutical security. Ergonomical and secure handling Quick and easy operation With the focus on ergonomics and cleanability, our engineers The machine table-top is seamlessly machined as one piece. have developed a machine that minimizes change-over and This allows for large-radius contours without undercuts, accor- cleaning times and therefore maximizes productivity. The ding to proper GMP design. Furthermore, only FDA-approved cgmp-compliant production cabin ensures easy accessibility materials are used. The maintenance-free main drive makes and user-friendly operation and cleaning. Likewise, machine the machine quiet in operation, reduces wear, and extends the sub-assemblies are quick and easy to exchange during for- machine s service life.. mat changeovers, for example. Machine control is via the touch-screen HMI, and is especially user-friendly. The control of the machine and measurement data collection are handled via an industrial PC. All production data is also saved and managed on the industrial PC. The Windows-based software complies with the data security guidelines of 1 CFR part 11. ADVANTAGES AT A GLANCE Highly accurate dosing Simple operation cgmp-compliant design Flexible dosing possibilities Low-maintenance operation Data security Reliability Optimal accessibility
GKF 500 The GKF 500 is a versatile and flexible machine that provides a great range of fill options for varying product types. Even complex products with varying fill parameters are easy to process. Thanks to the modular design of this capsule filler, the machine can be changed over in the minimum amount of time. GKF 500 ASB 100 % The GKF 500 ASB 100% is equipped with an integrated checkweigher. Every capsule produced on the machine is individually and precisely weighed. Only capsules with a weight within the pre-set tolerances are accepted. Overand underweight capsules are rejected. GKF 3000 The GKF 3000 is based on the successful GKF 500 and sets a new benchmark in the pharmaceutical industry with its output of 175,000 capsules per hour. This machine is reliable, low-maintenance, and provides production security. As the fastest tamping pin principle machine on the market, the GKF 3000 offers precise dosing with minimal product loss. Powder or pellet products are gently filled and even products with varying fill parameters can be optimally filled via height-adjustable dosing disks. A special seal separates the production and drive cabin, thereby protecting the product from foreign contaminants. 3
Description of functions and dosing options 1 3 1 4 11 5 10 6 9 7 8 1 Capsule orientation and separation 7 Faulty-capsule rejection Capsule orientation and separation 8 Free for optional pellet or tablet station * 3 Capsule cap scanner (ASB function) 9 4 Free for an optional pellet or tablet station Capsule closing with capsule body scanner (ASB function) 5 Dosing station for powder/pellets via fixed or height-adjustable dosing disk, liquid filling station or micro-dosing station 6 Free for optional pellet or tablet station No ASB function available on the GKF 3000 * Optional pellet station on the GKF 3000 4 10 Individual capsule ejection with ASB function 11 Individual capsule ejection with ASB function 1 Segment cleaning with compressed air (ASB function)
Equipped with the respective filling station, the GKF series achieves precise filling results for everything from free-flowing to cohesive powders, as well as for products of a liquid or pasty nature. We will be happy to develop a customized solution for your products and product combinations regardless of their physical properties. Powder/pellets Dosing station with patented slide-gate technology for the filling of powder and pellets. For powders, the proven tamping pin method is used; with pellets, the exact dosing is achieved using a fixed or height-adjustable dosing disk. Pellets The pellet station is a gentle, precise, and compact option for dosing pellets with different characteristics. Micro dosing Highly accurate, agglomeration-free micro dosing of powders using a micro dosing wheel (e.g. for inhalation) at maximum output. Liquids The liquid station with its integrated drip retraction feature enables the precise volumetric dosing of everything from hydrophilic to thixotropic liquids. It also has the ability to heat or cool liquids during the filling process. (Micro-) Tablets The tablet station is a gentle and precise solution for dosing of single and multiple tablets into capsules. Combinations A wide array of product combinations are possible on the GKF series, thanks to its modular assembly. Customized solution Thanks to the open platform, the GKF series is a filling machine that offers the flexibiliy to meet any filling solution requirements of the future. 5
Optimal productivity via quality control Reliable operation via automatic troubleshooting ASB funktion Automatic troubleshooting during operation enables automated, continuous production and reduces downtimes, even without the intervention of an operator. The calibration strip in the empty capsule sorting magazine ensures that deformed or damaged empty capsules are removed even before they reach the filling station. The mechanical capsule cap scanner determines if there are blockages in the empty capsule infeed. A repeated missing capsule in a particular segment bore is detected by the consecutive fault function. Deformed capsules in the capsule magazine are blown out via individual compressed air lines and rerouted to a separate deformed capsule container. The capsule body scanner detects incomplete capsules during capsule closing stopping incomplete capsule portions from making it into the good capsule production container. Capsules that have been determined to be faulty are individually rejected at the 18 capsule ejection flaps. The segment cleaning station uses compressed air nozzles to loosen sticky products and capsule fragments from the segment bores and reliably vacuum them away. This station ensures the cleaning of all the segments for the next filling cycle. Mechanical capsule cap scanner 6 Single capsule ejection of faulty capsules
The GKF 500 series guarantees optimal productivity and pharmaceutical security in capsule filling with its automatic troubleshooting feature (ASB) for the GKF 500 ASB and GKF 500 ASB 100% versions. GKF 500 ASB 100% with online weight control The analysis software calculates an average fill weight from Beyond the advantages of ASB, the integrated weighing sys- the checkweigher results and compares this average to the tem offers you a secure and documented production process. theoretical fill weight. If a capsule is outside the tolerance range, it is automatically rejected. The incident will then be The highly accurate weight-control feature automatically con- documented in the production report. trols fill weights with its pneumatic adjustment of the tamping pin pressure. This ensures that the desired fill weight is maintained within the specified tolerance range for the entire production process. The electrical height adjustment of the dosing disc allows for automatic regulation of the filling volume. This ensures a dosing weight within the required tolerance limits throughout the entire production process. ADVANTAGES AT A GLANCE Out-of-tolerance capsules are automatically rejected Reduction of machine downtimes Lights-out operation The capsule filling machine can be operated with or without the 100% checkweigher The checkweigher can be operated with or without the capsule filler Automatic, electric height-adjustable dosing disc 7
Description of functions 100% check weighing 1 3 4 5 6 7 8 9 10 8 1 Capsule hopper 6 Separating flaps Insertion pusher 7 Transport finger 3 Magazine 8 Weighing cell 4 Calibration bar 9 Transport wheel 5 Size plate 10 Discharge flap
Accurate weighing method Easy, fast cleaning The Bosch patented hanging weigh cell principle safely Due to the hermetic separation of the production and drive sec- weighs all capsules while avoiding dust or residue build up tion (balcony design), there is no contamination of the product within the weighing cell. In addition, the weigh cell design eli- and the machine is easy to clean. minates electrical interferences such as electrostatic fields. Standard automatic trouble shooting (ASB) Dependable production documentation The ASB function automatically detects and ejects deformed Data for the entire production run is stored and digitally capsules, helping to eliminate unnecessary downtime and evaluated by the user-friendly operating system. All of the data increase productivity. available on the system can be saved on the integrated DVD Burner or transferred to an external system via the USB port. Size changeover in < 1 min The ergonomic design, which sucessfully meets cgmp requirements, permits a size changeover in less than one minute. All change parts can be quickly disassembled without tools, allowing for rapid cleaning with no residues. KKE 500, the precise checkweighing unit for the GKF 500 9
Technical data Machine cycles Infeeds Formats Max. 140 cycles/min. Powder infeed Triclamp DN 150, Capsule format set for all standard Electrical connection Pellet/tablet infeed Triclamp DIN 3676 380 480 V, 50/60 Hz 3 ph/pe Special voltages 16 kva total capsule sizes, 00 to 5, DB Options DN 100, DIN 3676 Empty capsule infeed Triclamp Height-adjustable dosing disc DN 100, DIN 3676 Filling options Maximum amperage Standard equipment Powder filling station 16A Base machine with integrated Pellet filling station electrical cabinet and built-in HMI Vacuum pump electrical connection Machine control: industrial-pc 1.85 kw, 50 Hz,, kw, 60 Hz Empty capsule hopper with minimum and maximum level Vacuum requirement 50 m³/h at 50 mbar Utility connections Compressed air supply Ø 13 mm Vacuum pump connection Ø 30 mm Dust collector connection x Ø 70 mm Vacuum pump electrical connection Jogging cable connection Dust collector electrical connection Main electrical connection Liquid filling station² Tablet filling station for various tablet forms² Micro dosing station² control sensors Dosing station with fixed or Accessories height-adjustable dosing disc Vacuum pump for capsule separation and product container Dust collector Product container with minimum and maximum level control¹ Adjusting device for reproducible height-adjustment of the dosing disc Capsule closing station Automatic powder feeding Empty capsule feeder Capsule polisher Metal detector Distribution system with concave closing pins Cleaning station with compressed air nozzles and vacuum suction¹ ¹ optional on GKF 500 and GKF 3000 ² not on the GKF 3000 GKF 500 500 ASB 500 ASB 100 % 3000 Output (max. capsules/h) 150,000 150,000 150,000 175,000 Segment bores 18 18 18 1 Compressed air consumption (m3/h at 5 bar) 0 ca. 3,300 ca. 1,700 Dust-collector electrical connection 00 0 380 400 V 50 Hz, x.55 kw 0 30 380 400 460 480 V 60 Hz, x.55 kw Dust-collector air flow volume 80 m³/min, open suction Weight (kg) ca. 1,700 10 ca.,000
07 07 1389 0 Layout and top view 76 76 07 07 07 07 466 466 GKF 500 / GKF 500 ASB / GKF 3000 30 0 1389 1389 76 GKF 500 ASB 100 % 466 466 07 07 07 343 07 76 30 1389 1389 3061 76 Customized after-sales support service solutions for the entire life cycle of your machines 466 07 343 an extensive range of after-sales services. 07 By investing in a Bosch packaging machine, you gain access to We are always there for you: providing reliable services from a single source, all over the world. It already begins during the project phase with services such as process consulting, system planning, or lab services. And it continues during operation: 3061 from spare parts and field service offerings to stock optimiza- 1389 tion, modernization, and preventive maintenance, all the way to remote and data-based services and training. Whether it s a customized solution or a standard service together with us For more detailed information please visit our website: you achieve maximum output with minimum downtime and http://www.boschpackaging.com/en/pa/services/ optimize the profitability of your machines. after-sales-services/service.html 11
Product Division Pharma Solid Stuttgarter Straße 130 7133 Waiblingen Germany Phone +49 711 811-0 www.boschpackaging.com packaging-ph@bosch.com PA-PH 04.18 100 % chlorine free paper All rights reserved Technical data subject to modification without notice Robert Bosch Packaging Technology GmbH